Molded manufacturing for modular furniture

ABSTRACT

A method for manufacturing a furniture frame using molding techniques. A structural base is molded to create the base structure for modular furniture. Cushioning material is secured on the base structure of the modular furniture and layer(s) of upholstery material are applied over the cushioning material secured on the base structure.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to and the benefit of U.S. Provisional Application No. 62/806,516, under 35 U.S.C. 119(e), filed Feb. 15, 2019, entitled INTEGRATED MANUFACTURING FOR MODULAR FURNITURE, which is herein incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION 1. The Field of the Invention

This invention is in the field of furniture and manufacturing of furniture. In particular, the present invention relates to apparatus and methods of manufacturing modular furniture components.

2. The Relevant Technology

Modular furniture can be used to create customized furniture, such as sectionals, couches, chairs, beds, and other furniture items. Modular furniture components are generally manufactured using base members and transverse members that require frames, cushioning, and upholstery. During the manufacturing process of modular furniture components, it is often necessary to manufacture multiple parts and then separately assemble the multiple parts together to form, for example, a frame of a base structure.

For example, the frame of a modular furniture base structure may include cutting multiple wooden pieces and securing them together via fasteners such as screws, nails, staples, adhesives, and the like. Additional hardware, such as furniture feet, springs, and the like, are then added to the frame separately using more hardware, as noted above. This manufacturing process is time consuming and can be complex and unreliable when a large number of parts are required.

Additional assembly, including securing cushioning and upholstery to the base structure or frame, adds additional complexity that can be time consuming and costly. Increased manufacturing and assembly steps increase the likelihood of errors and defects appearing in the finished modular furniture components. Also, a large number of assembly steps in the manufacturing process leads to inconsistency and variations between finished components, which further requires additional quality assurance processes. These processes add to the cost and affect efficiency of manufacturing modular furniture components.

Accordingly, there is a need for apparatus and methods of manufacturing modular furniture components that solve these and other problems.

BRIEF SUMMARY OF THE INVENTION

During the manufacturing process of modular furniture components, it is often necessary to manufacture multiple parts and then separately assemble the multiple parts together to form furniture pieces. This method of manufacturing can be costly, labor intensive, and can lead to errors in production.

The present invention is in the field of furniture and manufacturing of furniture. In particular, the present invention relates to apparatus and methods of manufacturing modular furniture components.

One method for manufacturing modular furniture includes molding a structural frame, securing cushioning around the structural frame, and applying upholstery to the structural frame.

In one or more embodiments, a method for integrally manufacturing modular furniture components includes molding a structural frame that includes a hollow body with a side or face (e.g., top face) that is at least partially open. The structural frame can also include a spring mechanism secured to the body that spans the open side or face of the body. In one embodiment, an integrally manufactured furniture component includes a structural frame molded to be at least partially hollow. In one or more embodiments, there is a spring mechanism created in a separate process, or as part of another process. Such processes could include creating a molded structure, e.g., of metal or a polymeric or other suitable material. After the completion of the creation of the spring mechanism, it is attached to the molded frame and is secured to the frame by means of a fastener, such as screws, nails, etc.

Alternatively, in one or more embodiments, springs are molded across an open side or face of the structural frame. Such molded structures can be formed of polymeric (e.g., thermoplastic polymer) materials. In addition, the furniture component includes a cushioning material secured around at least a portion of the outside of the base structure, so as to cover the base structure (e.g., but not the springs), with upholstery fabric secured thereto.

In one embodiment, a cushioning material is added using fasteners, such as an adhesive or staples. In one or more embodiments, the cushioning material may be added by processes like molding, such as a spray foam process.

In addition, the furniture component can include a cushioning material secured around the outside of the structural frame, so as to cover the frame structure (e.g., but not the springs), and upholstery fabric secured thereto. In one embodiment, an upholstery fabric is added by the use of fasteners, such as zippers, hooks, staples or Velcro.

The various manufactured components may include base members, and/or transverse members, e.g., for use in assembling a chair, couch, or the like, such as disclosed in U.S. Pat. No. 7,213,885 entitled MODULAR FURNITURE ASSEMBLY, herein incorporated by reference in its entirety. The modular furniture components and methods disclosed in the present application may be used in connection with numerous furniture assemblies, e.g., such as, but not limited to, any similar to those disclosed in (i) U.S. Pat. No. 9,277,826, entitled MOUNTING PLATFORM FOR MODULAR FURNITURE ASSEMBLY, (ii) U.S. Pat. No. 8,783,778, entitled MOUNTING PLATFORM FOR MODULAR FURNITURE ASSEMBLY, (iii) U.S. Pat. No. 7,963,612 entitled MODULAR FURNITURE ASSEMBLY, (iv) U.S. Pat. No. 7,547,073, entitled MODULAR FURNITURE ASSEMBLY, (v) U.S. Pat. No. 7,213,885 entitled MODULAR FURNITURE ASSEMBLY, (vi) U.S. Publication No. 2017/0367486 entitled MODULAR FURNITURE ASSEMBLY CORNER SEATING SYSTEM, (vii) U.S. Pat. No. 10,212,519 entitled ELECTRONIC FURNITURE SYSTEMS WITH INTEGRATED INTERNAL SPEAKERS, (viii) U.S. Pat. No. 10,236,643 entitled ELECTRICAL HUB FOR FURNITURE ASSEMBLIES, (ix) U.S. Pat. No. 10,143,307 entitled FURNITURE SYSTEM WITH RECLINER ASSEMBLY, and (x) U.S. Pat. No. 10,123,621 entitled FURNITURE SYSTEM RECLINER ASSEMBLY WITH SLED RAILS, each of which is herein incorporated by reference in its entirety.

By way of example, the furniture components manufactured according to embodiments described herein can be components of a modular furniture assembly, such as those described in the above referenced patents. Such modularity allows the furniture components to be selectively separated from and coupled to one another, for easier transportation and storage. Such modularity can also allow various furniture assemblies to be assembled from a small number (e.g., 2) of basic components (e.g., bases and transverse members). The modularity can allow a given transverse member to serve interchangeably as a backrest or armrest. In one embodiment, the length of the base is substantially equal to the sum of the width of the base and the width of the transverse member. The transverse member can be conveniently interchangeable as a backrest or armrest in a variety of different furniture configurations. Such modularity allows a variety of furniture configurations to be formed from the base and transverse member, or from duplicates of those components, e.g., two bases and four transverse members can be used to form a sofa, for example, or a variety of different furniture configurations such as shown in the above patents.

These and other objects and features of the present invention will become more fully apparent from the following description and appended claims or may be learned by the practice of the invention as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings.

FIG. 1A is a perspective view of an exemplary modular furniture assembly in the form of a chair, including a base and a plurality of transverse members.

FIG. 1B is a perspective view of another modular furniture assembly in the form of a chair, including a base and a transverse member.

FIG. 1C is an exploded view, illustrating how the transverse member(s) and base are coupled to one another.

FIGS. 1D-1E further illustrate how the transverse member(s) and base are coupleable to one another.

FIG. 2 schematically illustrates a process for integrally manufacturing a modular furniture component (e.g., a transverse member or base), according to an implementation of the present disclosure.

FIG. 3A-3C schematically illustrate a process for integrally manufacturing a modular furniture component (e.g., a base or transverse member), according to an implementation of the present disclosure.

FIG. 4 schematically illustrates how coverings (e.g., an outer skin or otherwise) may be provided during manufacture of modular furniture components, according to an implementation of the present disclosure.

FIG. 5 illustrates an example method for manufacturing a modular furniture component (e.g., base or transverse member), according to an implementation of the present disclosure.

FIG. 6 illustrates another example method for manufacturing a modular furniture component (e.g., base or transverse member), according to an implementation of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The manufacturing process of modular furniture can be time consuming complex and unreliable when a large number of parts are required. When many pieces need to be combined, a significant number of man hours must be spent assembling the furniture piece and checking quality to ensure proper assembly.

The apparatus and manufacturing methods disclosed herein provide a streamlined, simplified method of manufacturing modular furniture components. In particular, the methods described herein require minimal assembly, which lessens manufacturing time and cost. For example, manufacturing methods according to the present disclosure reduce the number of components needed to form a modular furniture base or transverse structure, thus reducing the labor associated with assembly thereof, as well as reducing quality assurance and other costly processes.

FIG. 1A is a perspective view of a modular furniture assembly in the form of a chair 10, one or more components of which may be manufactured according to the present invention. For example, chair 10 includes a base member 12, and one or more transverse members 14 coupleable to the base 12, to form such a chair or other modular furniture assembly. Furniture assembly 10 (e.g., a chair) includes a seat cushion 18 positionable over base 12, as well as a cushion 16 (e.g., for use as a seat back, against one of transverse members 14). Foot couplers 34 are shown for coupling feet 33 mounted on the bottom portions of transverse members 14 and bases 12 to each other, as described in Applicant's other patents and applications, already incorporated by reference.

FIG. 1B is a perspective view of a similar modular furniture assembly 10′ (e.g., also in the form of a chair), including a base 12 and a transverse member 14. A seat cushion 18 is shown positioned over base 12, for seating a user. FIG. 1C shows the seat cushion 18 exploded off base 12, illustrating how U-shaped coupler 15 can be used to couple any given transverse member 14 to base 12. Such coupler 15 can also be used to couple 2 bases 12 to one another, as described in Applicants other patents and applications, already incorporated by reference. FIGS. 1D-1E further illustrate the base 12, transverse member 14, and how they are coupleable to one another. As will be further described herein, bases 12 and/or transverse members 14 may be manufactured according to methods described herein, by molding. It will be apparent that numerous other furniture components could similarly be manufactured through molding processes as described herein, such that bases 12 and transverse members 14 are merely exemplary of modular furniture components that may be so manufactured. Other furniture components, whether modular or otherwise, may benefit from manufacturing processes as described herein. Further examples of components that are useful in connection with the present invention, or that can be made using the techniques taught herein are shown in U.S. Pat. No. 7,213,885, which is incorporated herein by reference, and Applicant's other patents incorporated herein by reference.

FIG. 2 illustrates steps of a method for integrally manufacturing modular furniture components, according to one implementation. In this implementation, the first step 110 is to mold a structural frame 118 as a single piece using a mold, e.g., with molding form pieces 112 a-112 b to ensure the frame is molded in a desired shape as a structural frame 118. The structural frame 118 can be molded as a hollow body with a top side or face that is at least partially open. FIG. 2 shows an implementation, wherein the structural frame 118 is made by direct injection 116 molding. Other implementations of a method for molding the frame structure can include other molding techniques generally known in the art, for example blow molding, compression molding, structural foam molding, gas assist molding and the like.

In one embodiment, one or more furniture support mechanisms are molded as part of the structural frame 118. For example, furniture feet are placed in the mold in appropriate positions so that when the structural frame 118 is molded, the feet are integrally formed with the structural frame 118. Also, for example, a recess, such as a threaded recess used to secure feet to the structural frame 118 or a recess used to accommodate a coupler that holds multiple bases 12 (or transverse members 14) together, can be integrally molded in with the structural frame 118. In an embodiment, the mold cavity itself may include space so that the material filled into the cavity to form structural frame 118 also forms feet, which would be integral with the structural frame, formed as a single piece of material with the structural frame 118.

In the illustrated embodiment, a second step 120 includes the removal of the first form pieces 112 a-112 b, in favor of applying a second mold, e.g., form pieces 136 a-136 b, for the purposes of molding the cushioning material 132.

A third step 130 of the method, according to the illustrated implementation of FIG. 2, includes molding a cushioning material 132 on the structural frame 118. This can be done using form pieces 136 a-136 b to implement the various methods of molding discussed above to shape the cushioning material 132. That is, the cushioning material 132 may be molded to the structural frame 118 using blow molding, compression molding and/or, as seen in this implementation, injection molding techniques (e.g., through injection molding port 134). For example, in one implementation, the cushioning material 132 can be molded around the structural frame 118 using heat and pressure, causing the cushioning material 132 to chemically and/or mechanically bond to the structural frame 118. In another implementation, the cushioning material 132 can be formed in such a way that it mechanically secures to the structural frame 118.

In one implementation, the cushioning material 132 can comprise a foam material. The material 132 may be different from the material from which structural frame 118 is formed (e.g., an injection molded rigid thermoplastic polymer for structural frame 118 versus a soft foam material for cushioning material 132). The cushioning material 132 is preferably a material comprising flexible, resilient, and durable material that provides a padded layer on top of and/or around the structural frame 118. The structural frame 118 is made of a more rigid material than the cushioning material 132, including hard plastics and other plastic or polymeric materials that are suitable for molding, as described herein. For example, in one implementation, the structural frame 118 comprises expanded polypropylene (EPP). Various other thermoplastic polyolefins and other thermoplastic polymers can be used.

In the illustrated embodiment, a fourth step 140 removes the second form pieces 136 a-136 b. The fifth step 150 allows the structural frame 118 and connected cushioning material 132 to be wrapped in upholstery fabric 152. Fifth step 150 includes applying upholstery fabric 152 over the cushioning material 132 which covers structural frame 118. In one implementation, the upholstery fabric 152 is secured over the structural frame 118 and cushioning material 132 using adhesives, hook-and-loop fasteners, sewn thereto with thread, or any other suitable attachment mechanism. In one or more implementations, the upholstery fabric 152 may be secured over the structural frame 118 and/or cushioning 132 via snaps, such as hem snaps that snap into a channel formed in the structural frame 118, buttons, clips, or via a sliding mechanism such as a zipper mechanism, or the like.

In one implementation, as shown at step 160, the upholstery fabric is configured as an upholstery fabric assembly that includes multiple sections or layers including a first fabric layer 152 and a second fabric layer 162 that can be secured separately or secured together and then secured over the cushioning material 132 that covers structural frame 118. In another implementation, the upholstery fabric 152 is formed together as a slipcover and the structural frame 118 and cushioning material 132 is inserted therein. In yet another implementation, the upholstery layer 152 is part of the cushioning material 132 (e.g., a skin layer of the cushioning material 132). In such an implementation, the cushioning material 132 and/or upholstery layer 152 may serve as both cushioning and upholstery or be integrally formed together.

The upholstery layers (152 and 162) of the fabric assembly of FIG. 2 can be different types of outer covers made of various materials, e.g., tweed, cotton, synthetic, blend, leather, etc. They may be selected (and exchanged by a user) to cover the foam molded inner cover, for example, as illustrated, for example, in U.S. Pat. No. 10,212,519, entitled ELECTRONIC FURNITURE SYSTEMS WITH INTEGRATED INTERNAL SPEAKERS, which is incorporated herein by reference in its entirety. The outer layer may be many different pieces with a variety of different densities. The top layer, which forms the inner cover, may be relatively firm, for example, so that when a person sits on it they would not feel the underlying rigid (e.g., wood or plastic) layers. Other foam portions may be softer. Such foam layers could be over molded over a molded frame, as described herein.

In the illustrated implementation of FIG. 2, the structural frame 118 is formed as a single, unitary piece. It can be appreciated that the structural frame can be formed as two or more pieces and subsequently molded, formed, or otherwise secured together, either via heat and pressure, adhesives, fasteners, or the like. Additionally, or alternatively, hardware, such as furniture feet, springs, bolts, threaded holes, clips, recesses, or other hardware can be integrally molded with the structural frame 118.

As noted above, in one or more embodiments, hardware necessary to secure multiple furniture components together, such as recesses, J-clips and/or other clips, latches, and the like, can be integrally molded into the base structure of the furniture components. Accordingly, two or more furniture components can be joined/secured together to form furniture pieces. The size, shape, and configuration of the furniture pieces comprising multiple furniture components can vary depending on the needs or wants of the manufacturer and/or end customer. Other furniture components can similarly be molded with the structural frame 118. These embodiments may include, but are not limited to, molded feet for furniture pieces or molded hook Velcro for attaching fabric or cushioning. The structural frame 118 may represent a base 12, transverse member 14, or other component useful in assembling a furniture assembly, such as chair 10, 10′ of FIGS. 1A-1C.

The molded structural frame 118 can include webs, venting holes for providing airflow and/or decreasing the weight of the molded component, etc. as desired. Examples of such webbing structures, venting holes, and the like that can be molded as part of the structural frame 118 (e.g., as part of a base 12 or part of a transverse member 14) are described in the U.S. Provisional Application No. 62/806,516, to which priority is claimed herein and which is incorporated herein by reference, and/or in Applicant's U.S. patent applications bearing Attorney Docket Nos. 15605.245.2 and 15605.245.6, both filed the same day as the present application, and each of which is herein incorporated by reference in its entirety. By way of example, the molded structural frame 118 can be formed as a monolithic structure where feet, attachment structures, and/or other hardware associated with such structure, can be formed from a single piece of material (e.g., EPP). Alternatively, feet or other associated structures could be separately formed, for later attachment to the structural frame. The molded structural frame 118 can include web structures, cross-hatching, patterning, groove formation, or other patterns, venting holes, apertures, etc.

Attention is now directed to the embodiment of FIGS. 3A-3C which illustrate a furniture component that has been manufactured according to implementations of a manufacturing method described herein. First, as shown in FIG. 3A, the structural frame 118 is molded, as described above. As previously indicated, the structural frame 118 can take on any number of shapes, dimensions, and sizes. In the illustrated embodiment of FIG. 3A, the structural frame 118 is a substantially hollow rectangular prism (solid) structure. The structural frame 118 has a side or face that is at least partially open to expose the inside of the hollow rectangular prism. In the illustrated embodiment, the top face of the structural frame 118 is open.

Also illustrated in FIG. 3A are a number of springs 200 that span the opening in the top face of the structural frame 118. In one implementation, the springs 200 comprise elongated strips of material. In one embodiment, the material, for springs 200 is the same material as that of the structural frame 118 (EPP). For example, the structural frame 118 of FIGS. 3A-3C can be molded as a single unitary piece that includes the springs 200 and the remaining portion of structural frame 118. In one or more other implementations, the springs 200 comprise material that is different from the remainder of the structural frame 118. The spring materials are preferably durable and at least somewhat flexible or elastic so that the springs 200 flex without breaking or permanently deforming when a force is applied from above. Such a force, for example, may result from a person sitting or lying on the structural frame 118 (e.g., on the open end thereof, against springs 200).

In one embodiment, the springs 200 comprise elongate strips of material that span the opening in the top face of the structural frame 118. As seen in FIG. 3A, a plurality of springs 200 span the opening. The number, size, shape, and materials of the springs 200 may vary between embodiments of the furniture component of the present disclosure.

As mentioned, in one embodiment, such as shown in FIG. 3A, the springs 200 are integrally molded with the remaining structural frame 118, all as a single molded piece. Alternatively, in one or more other embodiments, the springs 200 are formed separately and then secured to the remainder of the structural frame 118. In such an embodiment, the springs 200 are secured to the structural frame 118 by welding, adhesion, mechanical fit, screws, bolts, or the like.

FIG. 3B further illustrates a step of securing a cushioning material 132 around the structural frame 118. As shown, the cushioning material 132 is secured around the outside perimeter (e.g., bottom face and sides) of the structural frame 118 as well as portions of the top face of the structural frame. In the illustrated embodiment, the cushioning 132 does not extend over the springs 200. In one or more other embodiments, the cushioning material 132 may extend at least partially or totally over the springs 200. The cushioning material 132 can be secured to the structural frame 118 in a number of ways. For example, in one embodiment, the cushioning material 132 is secured to the structural frame 118 using adhesives/glues.

Additionally, or alternatively, the cushioning material 132 is secured to the structural frame 118 by mechanically interlocking with the structural frame 118. Also, in one embodiment, the cushioning material 132 is molded to the structural frame 118 (e.g., a 2-step molding process, where the cushioning material 132 is molded over the more rigid structural frame 118). For example, heat and/or pressure can be applied to the cushioning material 132 and the structural frame 118 to bond the cushioning material 132 to the material of the structural frame 118, either chemically or mechanically. In an embodiment, dedicated attachment mechanisms (e.g., adhesives/glue and/or clips such as J-clips) can be used, e.g., positioned between the two, to achieve the attachment.

The molding of cushioning material 132 to the structural frame 118 may substantially eliminate the need to cut cushioning material 132, for subsequent attachment to a furniture component. Instead, a precise registration of cushioning material 132, such as flexible foam, can be molded to the structural frame 118. In such a method, no cutting is necessary, which reduces material waste and saves time during the manufacturing process.

Additionally, FIG. 3C illustrates a third step for integrally manufacturing a modular furniture component. In the third step, upholstery fabric 152 is secured to the furniture component over the cushioning material 132 which covers structural frame 118. One or more sections or layers of fabric, as seen in FIG. 2, at 152 and 162, can be used to cover the furniture component so that the cushioning material 132 is not exposed. Various fabrics or other materials can be used for the upholstery material 152. For example, in one embodiment, twill fabric is used as the upholstery material 152. Other embodiments may use upholstery fabric comprising fabrics other than twill. In an embodiment, such an upholstery material (e.g., twill) may be provided as an inner liner, which covers the underlying frame components of the base, transverse member, or other furniture component. An outer cover (e.g., layer 162) may be selected based on the preference of the end user, for positioning thereover, providing esthetics desired by the end user.

In one embodiment, the upholstery fabric 152 is secured to the cushioning material 132 and/or structural frame 118 materials using an adhesive. In one or more other embodiments, other methods may be used to secure the upholstery 152 to the furniture component. For example, in one embodiment, the upholstery 152 is sewn to the furniture component. Also, for example, in one embodiment, the upholstery material 152 is formed together as a slipcover and the furniture component is inserted therein. In yet another embodiment, hook-and-loop fastening methods, such as Velcro, can be used to secure the upholstery fabric 152 together and on/around the furniture component. Also, more than one type of fabric, as well as multiple independent sections of said fabric, can be used to cover the furniture component.

In addition to securing upholstery material 152 around the outside of the structural frame 118, one or more embodiments include upholstery material 152 that is secured to an inner side of the structural frame 118. For example, as noted above, one embodiment of the structural frame 118 is hollow so that the structural frame 118 possesses inner surfaces. In one embodiment, at least a portion of the inner surfaces of such a structural frame 118 are also covered in upholstery fabric 152. Upholstery fabric 152 is secured to the inner surfaces of the structural frame 118 in the same way upholstery fabric 152 is secured to the outer surfaces around the base structure 118, as described above, such as by chemical or mechanical means, including glue, adhesives, Velcro, snaps, or clips such as J-clips. The upholstery fabric secured to the inner surfaces of the structural frame 118 may comprise the same or different materials as the upholstery fabric secured around the outside of the structural frame 118.

FIG. 4 illustrates an embodiment showing molding examples to make transverse members 314, using methods of the present invention, e.g., to make transverse members similar to transverse member 14 of FIGS. 1A-1E. Parts or all of the transverse members 314 of the present invention can be molded in a variety of different manners. In some embodiments, foam 330 may be molded onto frame portions 332 of the transverse members, such as using a molding technique as shown in the perspective sectional view at 340. FIG. 4 shows an exemplary foam 330 that may be molded integrally or otherwise attached onto a transverse member frame 332 to form the transverse member 314 shown. The foam may include an outer “skin” layer 320 (serving as an upholstery layer, such as inner liner layer 152) that is integrally formed as the outer surface of the underlying cushioning material 330. Such a skin layer 320 may be substantially smooth, while the underlying cushioning material 330 may have a cushioned foamed (e.g., open or closed cells) structure. For example, some polyurethane materials are capable of forming such an exterior smooth “skin layer” over the remainder of the polyurethane material, which assumes a cushioned foamed, cellular configuration. Other skin forming foam molding materials will be apparent to those of skill in the art. By integrating the skin 320 and cushioning foam 330 that make up the exterior surface and cushioning portion of member 314, the manufacturing process can cut down on time that would normally be required to perform the tasks of applying a fabric cover (e.g., upholstery inner liner 152, where an outer layer 162 may eventually also be provided) and the foam cushioning material 330 individually.

In another embodiment, rather than automatically forming such an integral skin layer 320, a liner material (e.g., a fabric cover, which can eventually serve as an inner cover) could be positioned within the mold, as the foam layer of the cushioning material is being formed about the structural frame. Such a liner material can bond to the cushioning material as the cushioning material is molded about the frame “core” of the furniture component. Such a method can also result in a structure where the furniture component includes a desired liner (e.g., inner cover) as it is removed from the mold.

Attention is now directed to FIG. 5, which shows a flowchart of steps associated with exemplary methods, such as method 400. For example, at 410, a first molding process is used to create a single piece structural frame (a transverse member frame) for the modular furniture component. The molding process can be as previously described. That is, the molding process can implement methods such as injection molding or blow molding or other techniques known in the art.

At 420, a second molding process is used to create flexible foam cushioning in designated locations around the structural frame of the base or transverse member. As described herein, this foam can be created through various suitable molding techniques. The cushioning material can be molded directly over the structural frame, e.g., formed integrally thereto, such as in a 2-step molding process, or can be attached via fasteners such as nails, screws, or staples, or with a glue or other adhesive.

At 430, upholstery is attached around the flexible foam that covers the structural frame. The upholstery, as described herein, can be applied to the frame and foam via fasteners such as nails, screws, or staples or with a glue or adhesive. The upholstery could also be applied as a slipcover and closed with zippers or the like. As described herein, the upholstery layer could be an integrally formed “skin layer” that forms during molding or other formation of the foam layer. Where desired, a second upholstery layer can also be provided (e.g., an inner liner, and an outer cover).

For example, FIG. 6 illustrates such a method 400′ where at 410 the first molding process creates the structural frame of the modular furniture component in one piece. At 420, a second molding process results in creation of a flexible foam cushioning material in designated locations around the structural frame, and at 430′, such second molding process is configured to also provide an integral outer “skin” layer, e.g., automatically, during such molding process. Such outer skin layer can serve as a liner layer about the modular furniture component. At 440, an outer covering upholstery layer (e.g., outer cover) can be selected or provided for positioning over the liner layer provided by the integral skin layer. For example, the end user could select an outer cover of a desired material, color, etc. according to their own personal tastes, which provides the actual outer upholstery material seen by end users of the furniture assembly.

The present invention may be embodied in other specific forms without departing from its spirit or characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. 

1. A method for manufacturing a furniture component, the method comprising: molding a structural frame; securing cushioning material to the structural frame; and applying upholstery material to cover the cushioning material.
 2. The method of claim 1, wherein the structural frame is molded as a single piece.
 3. The method of claim 1, wherein the upholstery material also covers at least a portion of the structural frame.
 4. The method of claim 1, wherein the cushioning material is secured to the structural frame via an adhesive.
 5. The method of claim 4, wherein the upholstery material is applied to the structural frame and cushioning material via an adhesive.
 6. The method of claim 1, wherein the cushioning material is secured to the structural frame via mechanical interlocking.
 7. The method of claim 1, wherein the upholstery material is formed as a slipcover that is applied to the structural frame and cushioning material so that it at least partially surrounds the structural frame and cushioning material, the slipcover upholstery material aiding in securing the cushioning material around the structural frame.
 8. The method of claim 1, wherein the furniture component is a base or a transverse member of a modular furniture assembly.
 9. The method of claim 1, wherein applying upholstery material to cover the cushioning material comprises molding a skin layer over the cushioning material.
 10. The method of claim 1, wherein applying upholstery material to cover the cushioning material comprises molding a polyurethane skin over the cushioning material.
 11. The method of claim 1, wherein the structural frame comprises: a hollow body having a side or face that is at least partially open; and a spring mechanism secured to the body and disposed so as to span over the at least partially open side or face of the hollow body.
 12. (canceled)
 13. (canceled)
 14. The method of claim 11, wherein the structural frame is molded as two or more pieces which are then secured together.
 15. (canceled)
 16. The method of claim 13, further comprising molding hardware into the structural frame.
 17. The method of claim 11, wherein the spring mechanism comprises an elongate portion of flexible material that spans the open side or face of the body of the structural frame.
 18. (canceled)
 19. (canceled)
 20. The method of claim 11, wherein the upholstery material comprises both an inner layer and an outer layer, wherein the inner layer is an integrally formed skin that forms over the cushioning material during molding of the cushioning material over the structural frame, wherein the outer layer of the upholstery material comprises a separate fabric layer selected for placement over the inner layer to provide desired esthetics selected by the user.
 21. A furniture component of a modular furniture assembly, the furniture component comprising: a structural frame molded to be at least partially hollow; one or more springs molded across an open side or face of the structural frame; a cushioning material secured around an outside of the structural frame so as to cover the structural frame but not the springs; and upholstery fabric secured around the structural frame, springs, and cushioning material.
 22. The furniture component of claim 21, wherein the one or more springs comprise an elongate material secured to the base structure, the springs spanning the open side or face of the structural frame.
 23. The furniture component of claim 21, wherein the structural frame is a single integrally molded piece of plastic.
 24. A method for manufacturing a furniture component, comprising: molding a structural frame; and molding cushioning material onto the structural frame, the cushioning material having an outer skin exterior layer, wherein the furniture component can be selectively coupled to another furniture component.
 25. (canceled)
 26. (canceled)
 27. (canceled)
 28. (canceled)
 29. (canceled)
 30. A furniture component of a modular furniture assembly, the furniture component comprising: a molded structural frame; cushioning material molded onto the molded frame, wherein the furniture component is a base or transverse member of a modular furniture assembly.
 31. The furniture component of claim 30, wherein the cushioning material has an outer skin layer.
 32. The furniture component of claim 31, further comprising a fabric layer mounted on the outer skin layer.
 33. The furniture component of claim 31, wherein the outer skin exterior layer is substantially smooth while the underlying cushioning material has a cushioned foamed structure.
 34. The furniture component of claim 30, further comprising a fabric layer mounted on the cushioning material.
 35. The furniture component of claim 30, further comprising a coupler for selectively coupling the furniture component to another component of a modular furniture assembly. 